Method of making heavy parts of machinery, and the resulting products



Oct. 8, 1940. F, c HASSE METHOD OF mum HEAVY PARTS OF MACHINERY, AND THE RESULTING PRODUCTS Filed Aug. 27, 1938 2 Sheets-Sheet l g i l- ,1. 7 l j Z. r I f i 3 1 W l I 1| l 6 I a I l h L--- If" V Ill N I bi I m ll. n 1 I J .2 I, M; I 'mvENTb' 0 15 T:- 5 4 FRANK c HASSE ATTORNEY F. C HASSE 2216774 AND THE RESULTING PRODUCTS Oct. 8, 1940.

METHOD OF MAKING HEAVY PARTS OF MACHINERY,

2 Sheets-Sheet 2 Filed Aug. 27, 1938 ill! llh INVENTOR FRANK C. HASSE ATTORNEY Patented Oct. 8,v 1940 METHOD OFMAKING HEAVY PARTS OF MA- CHINERY, AND THE RESULTING PRODUCTS Frank C. Hasse, Chicago, 111., assignor, by mesne assignments, to Union Carbide and Carbon Corporation, a corporation or New York Application August27, 1938, Serial No. 227,086

17 Claims. (01. 39-448) UNITED STAT PATEN OFFICE This invention relates to heavy parts of machinery, such as locomotive cross-heads and driving boxes and, more particularly, to heavy machinery parts which are flame-cut from a single forged or rolled steel billet; and to a method of making such heavy machinery parts.

It has been customary to form heavy ma chinery parts, such as locomotive crossheads and driving boxes, of cast steel, making the castings of substantially the finished shape and machining the surfaces of parts which are to be fitted. Such heavy machinery parts, however, are subject to the defects and uncertainties of castings, and the breaking of such parts is almost certain to result in propery damage, and possibly even personal injury.

One object of the invention, therefore,isto provide heavy machinery parts which will have the properties of forged, rolled, or otherwise hotgo worked members and which will not be subject to the weaknesses of castings or their liability to breakage. Another object is to provide a simple method whereby heavy machinery parts, such as crossheads and driving boxes, may be 25 easily and economically cut from a steel billet, in order that billets instead of many different sizes of such heavy parts may be kept in stock in repair shops. These and other objects and the novel features will become apparent upon consid- 30 eration of the present specification.

The invention is illustrated by way of example in the accompanying drawings, in which:

Fig. 1 is a side View of two crossheads, the steel billet from which they are cut being shown 5 in broken line outline;

Fig. 2 is a plan view of the embodiment illustrated in Fig. 1;

Fig. 3 is a side view, similar to Fig. l, of two crossheads of a diiierent type;

40 Fig. 4 is a plan view of the embodiment illustrated in Fig. 3;

Fig. 5 is a side view of two locomotive driving boxes, the billet from which they are out being shown in broken line outline;

45 Fig. 6 is a plan view of the two "driving boxes illustrated in Fig. 5; and

Fig. 7 is an end view of the two driving boxes as seen from the right in Fig. 5.

I have found that heavy machinery parts may 50 be easily cut from a solid unitary steel billet by means of a suitable flame-cutting machine, for instance, using an oxygen cutting blowpipe. Instead of a flame-cutting machine, a hand cutting blowpipe may be used. The billet may be 55 supplied to the flame-cutting apparatus as lceived from the rolling mill, or the forging of the billet maybe performed in the same shop as the flame-cutting operation. I find it preferable to'cut or shape a single billet to provide, in one operation, a blank of two identical heavy machinery parts in connected relation with a common boundary-between them, and then to cut apart'along the common boundary the parts so formed to-produce two separate machinery parts which frequently are of substantially identical size and shape.- The steel billet desirably is of substantially rectangular cross-section and has the rough .form and outside dimensions of two of such parts-arranged end-to-end. The billet .is flame-cut-along' its six sides and between such sides-to closely approximate the form and dimensions of the two substantially identical machinery parts in end-to-end and axially aligned connected relation. The parts are cut apart by flame-cutting the billet along a plane centrally between the parts and perpendicular to the common axis of the'parts. The surfaces which require fitted contact with surfaces of cooperating members are machined, preferably before the severing operation which separates the parts, to

facilitate the machining operation. Any desired number of parts, however, may be out from a single billet by my method. Best results are obtained when the entire billet is first heated, that is to'say,'either taken hot from the rolls or the press which has forged it, or else raised from the cold state to the desired temperature for flamecutting. It is possible, however, to cut the machinery partfrom a cold billet by using greater volumes of the heating and cutting gases.

In Figs. 1 and 2 of the drawings there is shown in broken line outline-a steel billet B of substantially rectangular cross section from which a pair of alligator type crossheads C, C are cut to shape with a minimum waste of material. After the shaping operation has been completed, the two crossheads are still integrally connected by the stem elements 3, 3 to which piston rods are to be secured when'the crossheads are assembled on a locomotive. Each-element 3 is integral with a bifurcated body member 4 which has the usual shoes or gibs secured thereto when the crosshead is in the guides of a reciprocating engine.

The crossheads are formed by flame-cutting the two crossheads in one operation from the single billet B, along the outlines indicated in full lines in the drawings, to provide two identically shaped parts in end to end and connected relationship. Subsequently, the two crossheads are cut apart by flame severing along the central transverse line perpendicular to the common axis of the crossheads to provide individual crossheads having contour portions at opposite faces in each dimension fiame-cut to size. A hole 6 is also flame-cut in each bifurcation of each body member 4 to receive the usual pivotal wrist pin connection for a connecting rod. Por tions whichgreciujr'eg fitting, as'th'e edge surfaces 1 of th'ebifurcatibns against-which the shoes or gibs are fitted, are subsequently machined; or,

for convenience in handling, such portions may be machined prior to cutting apart the crossheads. 9 i

Thus, in cutting a pair of crossheadsa-s illus- I trated in Figs. 1 and 2, from the billet shown in broken lines, the billet is placed with theface illustrated in Fig. 2 upward. The complete contour of the side and end surfaces-ofthe two crossheads is then flame-cut from the billet, the material between the broken line outline of the billet, as shown inwFig. 2, and the crossheads as outlined in fullilines being cut away by the flame. During this operation the-recess 8, adapted to receive the end of .a connecting rod, is cut between the side surfaces of the billet, thereby forming-the. bifurcations of each bifurcated body, member 4. Following this, the billet is turned ,through 90- degrees. bringing the face illustratedin-Fig. -1 upwardandth'e complete outline .ofithetop, bottom, andends of the. two joined crossheads,:=;a's shown-in .full* lines in Fig, 1, is fiamercut;.at=-least to the depth of the upper bifurcations of :the body members 4, and'the holes 6,- ,6 are 'alsocut in-ea'ch ofthe upper bifurcations at thisgtime'. w-laNext; -.the workpiece :or block is turned.completely over, that is 3011888, through 180 degreesfr-until its opposite-sideis -up and the porrespoxrding cuts are made on this side, including-,completion of the cutoutlining the two joined-pistomrod attachment elements 3, 3 and, of cours e, the =holes.6,- 6 arranged; opposite and axially. .aligned with the holes 6, 6 in the upper bi u ations; Thesections 9,.9, between each pairofbifurcatmns,and the elements 3,- 3, may be cutoutwith-a hand torch; The last out of all is that along aperpendicular plane through the line 5,. which severs the twocrossheads. --In flame-cutting crossheads fromsolid steel billets inthe manner which has been described, it is preferableto use a heavy duty machine operated cutting blowpipe .and appropriate. patterns. orctemplets, in conjunction with such an apparatus asthat described in Patent No. 1,774,865,'granted September 2, 1930, to Isaiah Allison for {Blowpipe apparatus. As has been .preyiouslyindicated, it is possible to cut the crossheadsfroma cold billet if sufficient volumes of heating and cutting gases are used; but ;it is preferable to cut them from a billet which has been-previously heated. It has been found-that it'is mosteconomical and productive of the best'physicalsproperties in the resulting products toflame cut the billet while the same -is heated-.to. aatemperature-ofatleast 750 degrees Fahrehheit, Tand preferably one .heated to between. 750- and. 850 degrees Fahrenheit. By thus preheating the entirerbillet prior to the flame-cutting or shaping operation, the resulting product will be substantially free from strains and distortion throughout its mass. After flame-cutting the outlines of the two crossheads and the holes 6, and, if desired, before separating them by cutting along the line 5, the holes 6' in the members I are internally machined, and the faces I, "I on the edges of the bifurcations are machined for proper fitting with the bearing shoes which are fitted in contact therewith. It will be unnecessary, of course, to

machine other faces of the crosshead which do not require fitting or fitted contact with the surfaces of members cooperating with said crosshead, hence such other faces may be flame-cut to finished dimensions without lavingeicess stock along the'"'cuttingline for machining.

Figs. 3 and 4 illustrate another type of crosshead and how a pair of such crossheads may be cut froma single billet B of rectangular cross section. The crossheads C, C' are flame-cut from the billet B in a manner generally the same as the method employed for fabricating the crossheads C, C. The billet B, shown by broken lines,

is placed on edge on suitable supports with the face illustrated in Fig. 4 upward. First, the outline of the side and end surfaces of two bifurcated crossheads, having their bifurcations disposed in integral end-to-end relation, is flamecut in the twodimensions seen in Fig. 4, portions being cut to finished dimensions.v The interior out between the side surfaces is now started on the central'transverse'boundary line I2 and the interior contour I3 is out completely, thus providing a recess in each of the connected crossheads for the reception of the end of-a' connecting rod,- and forming the bifurcations;-Thebillet is :next turned through 90 degrees. withthe face illustrated in Fig, 3 and the starting out .12 upward, and the outside top,'.bottom, and end outline of the two crossheads as seenin this view is cut. After this, the holes I4, Mare-flame-cut, portionsbeing-cut to finished dimensionsfollow ing which the rectangular holes 15; .ISare cut, and then the outline I6 between crossheads. The faces I'I, I1, including the edges of the bifurcations, the holes I4, I4, and the holes I5, I5 may be cut to allow enough metal .for machining. The billet is next turned through 180 degrees and the corresponding contours and openings are flame-cut in the opposite side. The last cuts made are those corresponding to the outline I6,

which effect the final separation of the two crossheads. The sections marked I8, I8 .and the pis ton rod bores I9, I9 may be cut with a hand torch either before or after the two'crossheads have been otherwise flame-cut and separated.

After flame-cutting the oppositely arranged axially aligned wrist-pin holes I4, the surfaces I1, and the bores I9, these holes and surfaces may be machined, as are also the inset surfaces 20. The machining operations may be performed either before or after separation of the crossheads, as may be found convenient. However, to facilitate handling and simplify fabrication, it is advantageous to machine the crossheads while they are still in connected relation and before separating them.

Figs. 5, 6 and 7 illustrate the principles of the invention applied to the fabrication of a pair of unitary bifurcated locomotive driving boxes, showing how they may be cut from-a single rolled steel billet 2I of substantially rectangular'cross section.

According to this invention, the driving boxes 22, 22 are flame-cut from the billet 2| and machined by.substantia1ly the same general procedure employed for producing the crossheads, asalready described. The billet 2| may be placed on suitable supports with the face illustrated in Fig. 5 upward. The outline of two bifurcated dimensions seen in Fig. '5, including shoeand wedge channel clearances-H3, 23. Next, the interior contour 24 "is cut complete, including prominences 25, 25170 provide ledges and arcuate sockets 2 6, 26 to receive crown brasses. Thereafter, the central transverse severing cuts 21 maybe made. The core K, formed by cutting contour 24, desirably is removed .upon completion of the cuts 21 but may be'temporarily allowed to remain in position tohold the two driving or journal boxes together after the severing cut. Such core may be subsequently utilized forother purposes.

With the core K retained as a connecting means, the billet is then turned through 90 degrees with the face illustrated in Fig. 6 upward, and theoutside outline of'two', driving ,boxes as seen 'in this view is flame-cut, including the spring'saddle seat recesses 28, 28.' Thecore K formed by cutting contour 25, if retained in position, is next removed, permitting complete separation of the two journal boxes. The remaining operations may be performed upon the journal boxes individually, and if the core is removed prior to flame-cutting the recesses 28, 28 and other cuts shown in Fig. 6,

such recesses and cuts may alsobe performed upon the journal boxes individually. ,Wlth the face illustrated lung, 7 upward,' the shoe and wedge channels 29 are name-cutin each 'journal box, r nowingwmn the box is placed with the face illustrated'in Fig. 6 upward and the bottom contour 30 is 'cut thereon. After turning the box through 180 degrees, the cut corresponding tofcontour 30 is made on'fthe opposite side},v

Contours 28, 30 and '3l"at'the top and bottom of the driving box maybe flame-rout to finished dimensions or sufficient stock may be allowed for machining. In general, all surfaces which require fitted contact with surfaces of cooperating members should be flame-cut to leave sufiicient excess stock on the flame-cut surface for subsequent machining, and those which are e not subject to such contact may be flame-cut to finished dimensions. Thus, sufiicient metal should be allowed when, flameecutting the contour 24, including ledges 25 and brass-receiving sockets 26, so that these surfaces may be machined subsequently. Also, during the machining operations, spring saddle seats 32 may be milled, or drilled and chipped out of the top of the driving box. Oil cavities 33 may be subsequently drilled in they driving box, and also ducts 34 connecting the oil cavities with the innermost faces of the shoe and wedge channels 29.

It will'be evident that heavy machinery parts, such as crossheads and driving boxes, fabricated as described above, will have surfaces flame-cut to size and machined flame-cut surfaces, will have astrong and tough structure substantially throughout their masses characteristic of forged or rolled steel, and will not be subject to the weaknesses of steel castings. The invention makes possible a reduced inventory expense and other economies in railroad repair shops, since a relatively small stock of rolled steel billets is required as compared to a relatively large stock of assorted finished steel castings. Economies in labor and gas consumption are also afiorded by flame-cutting two or more machinery parts from a single billet during the same operation and setting. Furthermore, worn portions of a machinery part made of billet metal may be readily built up by the oxy-acetylene process, and thus the service life of a machinery part embodying this invention may be extended indefinitely.

The particular examples here illustrated and described are presented merely to indicate how the invention may be applied. It will be evident that certain features of the invention may be utilized independently of others; and various modifications, which do not depart from the principles of the invention, will be apparent to those skilled in this art.

This application contains subject matter in common with my copending application Serial No. 16,559; filed April 16, 1935.

I claim:

1. In a method of forming heavy parts 'of machinery, the steps which comprise providing a single steel billet having the rough form and outside dimensions of a plurality of such parts in connected relation and arranged to have comm'on boundaries between adjacent parts; flamecutting said billet to the desired contours of a plurality of such connected parts and separating the machinery parts so formed by flame-cutting along the common boundaries.

2. In a method of forming heavy parts of machinery, the steps which comprise providing a single steel billet having the rough form and outside dimensions of a plurality of such parts in connected relation and arranged to have com mon boundaries between adjacent parts; flame, cutting said billet to the desired contours of a plurality of such connected parts, but leaving suflicient excess stock for machining on those surfaces of saidpart's which require fitted contact with surfaces of cooperating members; ma,- chining'said parts 'to remove such excess stock; and separating the machinery parts so formed by flame-cutting along the common boundaries,

3. A method of forming a plurality of substantially identical parts of machinery such as locomotive crossheads and driving boxes, which comprises forging a single steel billet to the rough outside dimensions of at least two of such parts in end-toend and axially aligned relation; flamecutting portions of said billet to form said substantially identical parts in connectedrelation; machining surfaces of such connected parts which require fitting with surfaces of cooperating members; and separating the connected parts so formed and machined by flame-cutting perpendicularly to the common axis of and between such connected parts,

4. A method of forming two substantially identical heavy parts of machinery comprising providing a single steel billet having the rough outside dimensions of two suchparts arranged endto-end; flame-cutting the billet to the dimensions and form of two such parts in end-to-end and connected relation; and separating the connected machinery parts so formed by cutting along a plane centrally between said parts and perpendicular to the common axis of said parts to produce two separate machinery parts of substantially identical size and shape.

5. A method of forming heavy parts of machinery, which comprises providing a solid steel billet of substantially rectangular cross section and having the rough outside dimensions of two of such parts arranged end-to-end; flame-cutting said billet along its six sides and between such sides to the dimensions and form of two substantially identical machinery parts in end-toend relation; and severing said parts by flamecutting along a plane centrally between said parts and perpendicular to the common longitufore performing the severing operation to sepa-v rate them.

7. A method of forming heavy bifurcated parts of machinery, which comprises providing a single steel billet having the rough form and outside dimensions of two substantially identical bifurcated machinery parts having their bifurcations integrally joinedin end-to-end relation; flamecutting said billet to the desired exterior. contour of such joined parts; flame-cutting said billet tothe interior contour of said joined parts to form said integrally joined bifurcations; and severing said parts so formed by flame-cutting along the plane of Joinder of said bifurcations and perpendicular to the common axis of said parts.

8. A method of forming heavy bifurcated parts of machinery which comprises providing a single steel billet having a substantially rectangular cross section and the rough form and outside dimensions of two substantially identicalibifurcated machinery parts having'their bifurcations integrally joined in end-to-end and opposedrela-v tion; shaping said billet to the exterior contour of said joined parts in two dimensions by flamecutting; flame-cutting said billet to the interior contour of said joined parts in the afores'aidtwo dimensions to form the integral blfurcationsand 9. A method of forming crossheadscomprising providing a steel billet having the rough outside dimensions of 'two'crossheads arranged endto-end; flame-cutting said billet to the dimensions and form of two crossheads in end-to-end and connected relation; and cutting apart'the two crossheads so formed.

10. A method of forming crossheads comprising providing a steel billet having the rough outside dimensions of two crossheads; flame-cutting the two crossheads together from such billet; ma-' chining the surfaces of said crossheads which require fitting; and flame-cutting such formed crossheads apart.

11. A method of forming unitary steel crossheads comprising providing a solid steel billet of substantially rectangular cross section having the rough outside dimensions of two identical crossheads arranged end-to-end; heating said billet to between 750 and 850 degrees Fahrenheit; flame-cutting such heated billet'to the desired substantially finished contours of two identical crossheads in end-to-end and connected relation; and flame-cutting said crossheads apart to produce two separate identical crossheads.

12. A method of forming crossheads comprising forging a billet to the rough outside dimensions of two crossheads; heating the said billet to between 750 and 850 degrees Fahrenheit; flame-cutting such heated billet to the desired contours of two connected crossheads; machining the surfaces of said crossheads which require fitting; and cutting apart said two crossheads.

13. In a method of forming unitary steel crossheads, the steps which comprise providing a steel billet of substantially rectangular crosssection and having the rough outside dimensions of two crossheads arranged in end-to-end and connected relation; flame-cutting portions of two opposite faces of said billet to finished dimensions to form sidesurfa'ces of said connected crossheads; flame-cutting portions of the two end surfaces of said billet to finished dimensions to form end surfaces of said connected crossheads; flame-cutting said billet between such side surfaces to provide a recess in each of said connected crossheads adapted to receive the end of a connecting rod, thereby forming bifurcations on each of said connected'crossheads; flame-cutting two opposite surfaces of said billet to form the top and bottom surfaces of said connected crossheads, but leaving sufllcient metal on portions thereof for machining'to fit bearing shoes; flamecutting oppositely arranged. axially aligned holes in the bifurcations of eachcrossheadjtolreceive wrist-pins, but leaving sufficientl'netal for machining; machining said holes; .machining portions of the top andbottom surfaces of said cross heads, includingthe edges of said bifurcations, to fit with bearing'shoes; andgflame-cutting said crossheadsapart. I f I.

'14. A unitary steeljcrosshead made from a solid steel billet of substantially rectangular cross-section, said crosshead comprising bifurcations and having contouriaortions at opposite faces thereof'imeach dinignslon flame-Qcut to size, said crosshead havingioppo'sit'elyiarranged axially aligned holes in said bifurcations adapted to'receive a wrist pin, the walls of such holes comprising machinedflamecut surfaces, and said crosshead'having contour portions on the top and bottom surfacesthereof, including the edges of said bifurcations, comprising machined flame-cut surfaces adapted to engage and fit closely with healing shoes. I

15. A unitary crosshead blank made from a solid steel billet of substantially rectangular cross section, said 'crosshead "blank' comprising two connected crossheads having a common boundary therebetween, each 10f said connected crossheads comprising bifurcations and having contour portions at opposite faces thereof flamecut to size, each of said connected crossheads having oppositely arranged axially aligned holes in said bifurcations adapted to receive wrist pins, the walls of such holes comprising machined flame-cut surfaces, and each of said connected crossheads having contour portions on the top and bottom surfaces thereof, including the edges of said bifurcations, comprising machined flamecut surfaces adapted to engage and fit closely with bearing shoes.

16. A method of forming steel driving boxes comprising providing a single steel billet having the rough outside dimensions of two driving boxes arranged end-to-end; flame-cutting said billet to' the dimensions and form of two driving boxes in end-to-end and connected relation; and cutting apart the driving boxes so formed.

1'7. A method as set forth in claim 16, wherein said billet is heated to a temperature above about 750 F. prior to said flame-cutting operation, and the surfaces of said driving boxes which require fitting are machined after such flame-cutting operation.

FRANK C. HASSE. 

